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5.3.1
crack growth rate prediction. The similitude rules are a set of requirements on structural crack
geometry and the mode and extent of crack-tip deformation of a material under loading. A
discussion of similitude rules is presented by Leis, et.al.[1986].
The small crack effects have been observed in both notched and un-notched specimens. The un-
notched small crack growth behavior has been attributed to crack grain boundary interaction
effects not accounted for in the fracture mechanics based predictions of small crack growth. In
the case of long cracks, the crack growth in the plastic wake is averaged over many grains. It has
been argued by Leis, et al. [1986] and Blom, et al. [1986] that the difference in crack growth at
notches is not due to the breakdown of similitude rules but inaccurate calculations of the stress
intensity factors.
Based on observations of small crack growth in 2024-T3, Blom [Blom, et al., 1986] reported that
the short crack effects are due to plasticity induced crack closure and roughness induced closure
effects. He also concluded that in this material a crack should be al least four grains in length
before qualifying as a long crack. In Newmans [1992] study of small cracks in 2024-T3 and
7075-T6 specimens, the crack closure transients have been found to be the cause of crack growth
effects. There is transient behavior of crack opening stress as the crack progresses from small
crack size to long crack. At higher stress ratios (stress ratios over 0.5), the crack may be assumed
to be open and thus has no significant effect on crack opening stress. At higher negative stress
ratios (i.e. at R=-2), the effects have been found to be more significant. A fatigue crack growth
analysis computer code FASTRAN based on plasticity induced closure has been developed
and currently available at NASA Computer Management and Software Information Center.
Nagar [2002] studied small fatigue crack growth behavior at pin-loaded holes in structural joints
where small cracks are often observed. Experiments were conducted on 2024-T3 specimens with
0.003 inch single, thru-radial cracks. The rectangular panel specimens with two collinear central
cracks and doublers of varying stiffness were joined by close fit titanium pins. The doublers
provided the variation in load transfer rates at the fasteners holes. The loads of constant
amplitude with marker bands and spectrum loads were applied to the specimens.
A comparison of structural joint small crack growth data with FASTRAN predictions show that
FASTRAN predicts small crack behavior under constant amplitude loading reasonably well.
However, the plasticity induced closure based predictions by FASTRAN do not correlate with
the small crack growth data under periodic over loads (marker bands) as well. The predictions of
small crack life under spectrum loads (EIFS) were even farther off. In general, the crack growth
rates are lower than predicted. Thus there is a question whether FASTRAN can be employed
reliably to predict small crack growth in joints with loading histories.
The experimental strain data developed during this program also indicated that the load transfer
rates for steel doublers can not be predicted using the same technique as used in NASTRAN
which have been used for calculations of fastener load transfer with aluminum doublers. This
study was conducted under a co-operative FAA/Air Force/Boeing program and the details are
available in an Air Force Research Laboratory Report [Nagar, 2002].
5.3.2